Reconfigurable Battery Pack Switching for Lightweight Voltage Control

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Solution Overview

Problem

Solar and battery power systems for high-altitude, long-endurance aircraft are hindered by the additional weight and complexity introduced by maximum power point trackers and traditional battery packs.

Innovation Solution

A reconfigurable battery system with switchable battery modules that adjust their connection to a battery string based on parameters like state of health, open circuit voltage, internal resistance, and state of charge, using a battery pack controller to achieve a predetermined target output voltage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional battery packs with maximum power point trackers are used, then power management functionality is achieved, but weight and system complexity increase

Engineering Contradiction:
Improvepower management functionalityVSAvoidbattery pack weight
Core Design Contradiction:
Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent extracts the maximum power point tracking functionality from the battery pack system and implements it within the solar panel array itself through programmable switches. This separation removes the need for heavy external MPP tracker devices, reducing overall system weight while maintaining power management capabilities.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The programmable battery pack serves multiple functions: it stores electrical energy, performs maximum power point tracking, and provides power management all within a single integrated system. This multi-functionality eliminates the need for separate MPP tracker devices, reducing system complexity and weight.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Productivity

If maximum power point trackers are added to solar panels, then power extraction efficiency is improved, but device complexity increases

Engineering Contradiction:
Improvepower extraction efficiencyVSAvoidsystem complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the MPP tracking circuitry directly into the solar panel array structure, combining power generation and power management functions in one integrated system. This integration reduces the number of separate components and interconnections, thereby reducing system complexity while maintaining efficient power extraction.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The solar panel array performs self-regulation of power extraction through programmable switches that automatically adjust connections to achieve maximum power point tracking. This self-service capability eliminates the need for complex external control systems, reducing overall device complexity.

Inventive Principle:
Principle #25Self-service

3Manufacturing precision

If battery modules are reconfigured based on multiple parameters, then output voltage precision is improved, but control complexity increases

Engineering Contradiction:
Improveoutput voltage precisionVSAvoidcontrol complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements dynamic reconfiguration of battery modules based on real-time parameter monitoring. The system continuously adjusts switch configurations in response to changing operating conditions, enabling precise voltage control while using standardized switch components that manage control complexity through programmable automation.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS12381264B2Programmable battery pack
Publication Date: 2025.08.05 AURORA FLIGHT SCIENCES CORP
  • US12381264B2 patent drawing
  • US12381264B2 patent drawing
  • US12381264B2 patent drawing

AI summary

The present disclosure relates to a reconfigurable battery system and method of operating the same. An example apparatus includes at least one memory, instructions in the apparatus, and processor circuitry to execute the instructions to determine a state of charge of a battery, determine a closed circuit voltage of the battery, determine a value of a parameter based on a ratio of the state of charge and the closed circuit voltage, and control a switch coupled to the battery based on the value of the parameter, the controlling of the switch to either cause the battery to be coupled to a battery string or cause the battery to be disconnected from the battery string.